Waterless dyeing method and yarn produced by waterless dyeing

ABSTRACT

A polymer phase colored performance fabric is disclosed, which is formed of a fabric of a solution dyed yarn woven with an elastic yarn, the fabric comprising at least 60% by volume of the solution dyed yarn. The solution dyed yarn is formed of a synthetic substance in a polymer phase that is combined with a colored dye, the combination producing a polymer phase colorant comprising a masterbatch of colored chips, a portion of which is heated to a liquid polymer colorant. The liquid polymer colorant is extruded to form a thread-shaped colored fiber of the synthetic substance, which is then cooled to form the solution dyed yarn.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/885,410, filed Oct. 1, 2013, titled “Waterless Dyeing Method and Yarn Produced by Waterless Dyeing,” the disclosure of which is hereby incorporated by reference in its entirety herein.

BACKGROUND

Activewear fabrics are well known. Typically, activewear garments are made with non-solution dyed yarns, which may be colored by vat dyeing, cationic dyeing, atmospheric dyeing, batik, chain dyeing, cross dyeing, high-temperature dyeing, ingrain, jet dyeing, muff dyeing, pad dyeing, piece dyeing, printing, reserve dyeing, short-liquor dyeing, skein dyeing, solvent dyeing, stock dyeing, thermal fixation, union dyeing, yarn dyeing, space dyeing, pressure dyeing, dye sublimation, or the yarn may be natural in color. As used herein, “non-solution dyed yarns” refers to yarns that are not pre-colored by the addition of a pigment or dye to the polymer melt or spinning solution prior to extrusion of the yarn fibers. In other words, non-solution dyed yarns are dyed after the formation of the yarn fibers by various methods.

However, activewear fabrics made of non-solution dyed yarns will fade over time with repeated washing. Exposure to light, UV radiation, and inclement weather may also contribute to the fading of the activewear garments employing non-solution dyed yarns. Additionally, the color of the activewear garments can fade or discolor when chemicals, such as bleach, are spilled on the fabrics. Furthermore, traditional non-solution dyed fabric are incredibly water and energy intensive in the manufacturing process. Finally, soiling and stains can degrade the appearance and value of the activewear garments including those made with non-solution dyed yarns.

The use of performance activewear fabrics containing only solution-dyed yarns enhances the retention of color of the activewear garments. Because solution-dyed, otherwise referred to as dope dyed, mass dyed, or spin dyed fabrics are colored during the formation of yarn fibers, the colors of the fabrics are fast to most destructive agents, such as light, weather, and washing. Additionally, solution-dyed fabric requires zero water use during their manufacturing process because the coloration is achieved in the polymer phase of the yarn formation.

The energy and Co2 emissions are also greatly diminished in the creation of solution-dyed fabrics by comparison to non-solution dyed fabrics. Accordingly, it is one object of the present invention to quantify the beneficial water usage savings, energy output savings, and Co2 emissions savings of solution-dyed fabric on a per garment basis when directly compared to non-solution dyed fabric garments.

There remains a need for performance activewear garments that are made of fabrics that can better retain color without the use of water in a dyeing process, and in a manner that greatly reduces the environmental burden of their creation.

SUMMARY

This document describes polymer phase coloration for making performance activewear fabric, also referred to herein as solution-dyed yarn, that can be incorporated into any number of finished garments including, but not limited to, boardshorts, baselayer shorts, bikinis, sports bras, leggings, tights, underwear, and the like. A feature of the present invention is the use of a performance stretch fabric made of a combination of solution-dyed yarn and elastic yarn, with the preferable fabric weight between 100-200 g/m2, and more particularly 130 g/m2. The use of elastic yarns is advantageous, because these yarns add stretch and compression to the fabric. However, elastic yarns alone are inadequate to creating the desired performance fabric because they fail to prevent fading and staining resulting from exposure to such things as washing, weather, UV light, and chemical agents. Additionally, elastic yarns alone would not produce the desired fabric weight and hand feel. Therefore, the incorporation of solution-dyed yarn into the fabric aids in masking the effects of these destructive agents on the color and quality of the fabric. An additional feature of the fabric disclosed herein is the optional use of a durable water repellent additive, an ultraviolet (UV) radiation resistant additive, a luster-producing additive, or the like.

In one aspect, a method of producing a polymer phase colored performance fabric is disclosed. The method includes combining a synthetic substance in a polymer phase with a colored dye, the combining to produce a polymer phase colorant. The method further includes forming the polymer phase colorant into a masterbatch of colored chips, and heating at least a portion of the masterbatch of colored chips to melt the portion of the masterbatch to a liquid polymer colorant. The method further includes extruding the liquid polymer colorant to form a thread-shaped colored fiber of the synthetic substance, and cooling the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn. The method further includes weaving the solution dyed yarn with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.

In another aspect, a fabric is presented that is formed of a solution dyed yarn woven with an elastic yarn. The fabric includes at least 60% by volume of the solution dyed yarn. The solution dyed yarn is formed of a synthetic substance in a polymer phase that is combined with a colored dye, the combination producing a polymer phase colorant comprising a masterbatch of colored chips. A portion of the masterbatch of colored chips is heated to a liquid polymer colorant, which is then extruded to form a thread-shaped colored fiber of the synthetic substance, which in turn is cooled to form the solution dyed yarn.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects will now be described in detail with reference to the following drawings.

FIG. 1 shows an activewear garment, namely a boardshort according to an implementation of the present disclosure.

FIG. 2 illustrates a system for producing a polymer phase colored performance fabric.

FIG. 3 illustrates a waterless dyeing process for dyeing performance fabrics and yarns, suitable for activewear.

FIG. 4 is a flowchart to illustrate a method of producing a polymer phase colored performance fabric.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This document describes a performance activewear fabric made of solution-dyed yarns, which uses a dyeing technique that does not require the use of water such as with conventional dyeing techniques. The process

An embodiment of the present invention is a dyed activewear fabric 10 that is made of a fabric 12. As illustrated in FIG. 1, the fabric 12 is made of a combination of two types of yarn or thread. Specifically, the fabric 12 is formed from solution dyed yarn and elastic yarn. Otherwise referred to as dope dyed or spin dyed yarn, solution dyed yarn is a manufactured yarn that has been colored by the introduction of pigments or insoluble dyes into the polymer melt or spinning solution prior to extrusion whereby fibers are formed. Accordingly, elastic yarn is a yarn that adds the desirable characteristics of stretch and elongation to the fabric. For example, a desired fabric composition of the invention could consist of 87% solution-dyed synthetic yarn and 13% elastic yarn. Any desirable combination of solution-dyed synthetic yarn and elastic yarn may be used for the invention. Accordingly, there exist a number of configurations and embodiments that may be employed depending on the desired coloration and the intended use of the garment 10 that should not be limited by these described examples.

Although a wide variety of materials may be used to in the formation of the solution dyed yarn, including, but not limited to, nylon, polypropylene, polyester, acrylic, and glass, the solution dyed yarn is preferably formed from polyester. Further, the solution dyed yarn may be either dyeable (non-sulfonated) or non-dyeable (sulfonated). Although a darker shade of solution dyed yarn is preferable in the present invention, any color yarn may be used.

The elastic yarn may be made from a variety of either natural or synthetic material or both, such as, but not limited to, elastane (also known as Spandex), latex, rubber, or a combination thereof. Preferably, the elastic yarn is preferably formed from elastane, a man-made fiber often containing at least 85% polyurethane which is capable of high stretch followed by rapid and substantial recovery to its unstretched length. The thickness of the elastic yarn and the solution dyed yarn can also vary depending on the particular end use of intended garment 10. The thickness can be varied through the use of monofilament yarns and multifilament yarns in the fabric 12 of the present invention.

In the case that fine fibers are desirable, multifilament yarns can be employed having a range of thickness from about 15 to about 70 denier and, preferably, from about 30 to about 50 denier. In the case that heavy or more coarse fibers are used in the invention, monofilament yarns can be employed having a range of thickness of about 75 to about 250 denier, and, preferably, about 100 to about 120 denier. Of course, those persons skilled in the art will recognize that various other types of yarns may also be employed as necessary or desirable according to the fabric weight, feel, and other characteristics sought to be achieved.

Content: 87% recycled polyester+13% spandex

Yarn Count: 75D+40D*75D+40D

Weight: 130 gsm

Density: 127*97

In accordance with a preferred implementation, a single ply solution-dyed synthetic garment fabric includes a woven and/or knitted substrate formed of solution-dyed synthetic fabric. The substrate can include a coating, such as a water repellent or hydrophobic material coating on the substrate fabric. The woven and/or knitted substrate formed of solution-dyed synthetic fabric is preferably formed of a blend of solution dyed polyester yarn and elastic yarn in both the warp and weft. In a particular implementation, the polyester/elastic blend is preferably 87/13, but can be between 80/20 to 100 percent polyester yarn. The polyester can be of any desirable solution-dyed color.

The environmental benefits of the waterless dyeing techniques disclosed herein, when directly compared to traditional non-solution dyed fabric, include significant water conservation, lower energy usage, and lower Co2 emissions.

FIG. 2 illustrates a system 200 for producing a polymer phase colored performance fabric. The system 200 includes virgin resin 202 of a synthetic substance in a polymer phase, and one or more colored dyes 204. The virgin resin can be polyester, PET, or other synthetic substance, material, or composition. The colored dyes 204 can be any of a selection of custom color concentrates, and can be initially soluble or insoluble. The system 200 further includes a combiner 206 to combine the synthetic substance in the polymer phase with the colored dye, to produce a polymer phase colorant and form the polymer phase colorant into a masterbatch of colored chips.

The system 200 further includes one or more extruders 208 that receive the polymer phase colorant and form it into a thread-shaped colored fiber of the synthetic substance. The one or more extruders 208 can also be adapted with heating elements or heat bands to melt the portion of the masterbatch to a liquid polymer colorant of which the thread-shaped colored fiber is made. The system 200 further includes one or more coolers 210, such as cooling towers, fans, etc., that cool the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn. Finally, one or more entanglers 212 produce the solution dyed yarn for spooling on spool 214 or other suitable carrier. Accordingly, once the solution dyed yarn is produced, without using any water, it can be woven with an elastic yarn to produce the polymer phase colored performance fabric. In some preferred implementations, the polymer phase colored performance fabric is formed of at least 60% by volume of the solution dyed yarn.

In some implementations consistent with this disclosure, and as illustrated in FIG. 3, coloration occurs in the polymer phase before yarn extrusion via pigment master batches. The pigment master batches can be formed into a resin polymer chip 304, such as PET, and can include one or more performance additives 306, such as a flame retardant additive, a UV resistant additive, and a luster or look-enhancing additive. Other additives can be added to the virgin resin. The resin polymer chips 304 are fed to a hopper 308 and combined with custom color concentrates, which form a masterbatch of colored chips. The combination can include melting the virgin resin and any additives together with the custom color concentrates, which cool to form the colored chips. Alternatively, the combination can yield a solid bar or column of the colored masterbatch.

In some implementations, the colored masterbatch is fed to one or more extruders 312 with external heat bands, which heats and melts the colored masterbatch polymer to a liquid colored polymer. The extruder(s) 312 pass the liquid colored polymer to spinnerets 314 that have shaped holes for forming the liquid colored polymer into a particular elongated and shaped thread, and then to cooling towers 316, where the threads are cooled into wave-shaped fibers. These fibers can be entangled by an air jet 318, and then spooled onto thread spool 320 as a polymer phase colored performance fabric. Fabrics are knitted or woven to the customer's request. Yarn is extruded with color penetrating the entire fiber thereby skipping a water phase and a dye bath phase completely.

FIG. 4 is a flowchart to illustrate a method 400 of producing a polymer phase colored performance fabric. At 402, a synthetic substance in a polymer phase is combined with a colored dye, and at 404 a polymer phase colorant comprising a masterbatch of colored chips is formed. At 406, at least a portion of the masterbatch of colored chips is heated to melt the portion of the masterbatch to a liquid polymer colorant. At 408, the liquid polymer colorant is extruded or otherwise formed to a thread-shaped colored fiber of the synthetic substance, and at 410 the thread-shaped colored fiber of the synthetic substance is cooled to form a solution dyed yarn. At 412, the solution dyed yarn is woven with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.

Although a few embodiments have been described in detail above, other modifications are possible. Other embodiments may be within the scope of the following claims. 

1. A method of producing a polymer phase colored performance fabric, the method comprising: combining a synthetic substance in a polymer phase with a colored dye, the combining to produce a polymer phase colorant comprising a masterbatch of colored chips; heating at least a portion of the masterbatch of colored chips to melt the portion of the masterbatch to a liquid polymer colorant; extruding the liquid polymer colorant to form a thread-shaped colored fiber of the synthetic substance; cooling the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn; and weaving the solution dyed yarn with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.
 2. The method in accordance with claim 1, wherein the weight of the polymer phase colored performance fabric is between 15 and 70 denier.
 3. The method in accordance with claim 1, wherein combining the insoluble dye with the synthetic substance in the polymer phase further comprises includes enabling the insoluble dye to molecularly bond with the synthetic substance in the polymer phase.
 4. The method in accordance with claim 1, wherein the synthetic substance in the polymer phase is polyethylene terephthalate, and wherein the masterbatch of colored chips includes colored polyethylene terephthalate.
 5. The method in accordance with claim 1, wherein the colored dye is soluble, and wherein the masterbatch of colored chips is insoluble.
 6. A method of producing a polymer phase colored performance fabric, the method comprising: combining a synthetic substance in a polymer phase with a colored dye, the combining to produce a polymer phase colorant forming the polymer phase colorant into a masterbatch of colored chips; heating at least a portion of the masterbatch of colored chips to melt the portion of the masterbatch to a liquid polymer colorant; extruding the liquid polymer colorant to form a thread-shaped colored fiber of the synthetic substance; cooling the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn; and weaving the solution dyed yarn with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.
 7. The method in accordance with claim 6, wherein the weight of the polymer phase colored performance fabric is between 15 and 70 denier.
 8. The method in accordance with claim 6, wherein combining the insoluble dye with the synthetic substance in the polymer phase further comprises includes enabling the insoluble dye to molecularly bond with the synthetic substance in the polymer phase.
 9. The method in accordance with claim 6, wherein the synthetic substance in the polymer phase is polyethylene terephthalate, and wherein the masterbatch of colored chips includes colored polyethylene terephthalate.
 10. The method in accordance with claim 6, wherein the colored dye is soluble, and wherein the masterbatch of colored chips is insoluble.
 11. A polymer phase colored performance fabric comprising: a fabric of a solution dyed yarn woven with an elastic yarn, the fabric comprising at least 60% by volume of the solution dyed yarn, the solution dyed yarn being formed of a synthetic substance in a polymer phase that is combined with a colored dye, the combination producing a polymer phase colorant comprising a masterbatch of colored chips, a portion of which is heated to a liquid polymer colorant, which is extruded to form a thread-shaped colored fiber of the synthetic substance, which is cooled to form the solution dyed yarn.
 12. The polymer phase colored performance fabric in accordance with claim 11, wherein the fabric has a weight of between 15 and 70 denier.
 13. The polymer phase colored performance fabric in accordance with claim 12, wherein the fabric has a weight of between 30 and 50 denier.
 14. The polymer phase colored performance fabric in accordance with claim 11, wherein the elastic yarn is formed of elastane.
 15. The polymer phase colored performance fabric in accordance with claim 11, wherein the synthetic substance in the polymer phase is polyethylene terephthalate. 